Hats, Caps, and Methods for Manufacturing the Same

ABSTRACT

Disclosed are methods for manufacturing at least portions of hats and caps, as well as at least portions of hats and caps manufactured by the disclosed methods. In examples, provided are methods for fabricating a biretta, which can include (1) forming, using a hat block, a plastic biretta hat foundation from a heat-activated low-melt polyester fiber, (2) forming, using a horn block, at least one plastic biretta horn from the same type of heat-activated low-melt polyester fiber, and (3) fastening a plastic biretta horn along an exterior ridge of the plastic biretta hat foundation. An orifice can be formed in a peak of the plastic biretta hat foundation. At least a part of the plastic biretta hat foundation can be covered with a fabric cover. A twist rope or a pom fastener can be passed through the orifice to secure the twist rope or a pom to the plastic biretta hat foundation.

CROSS REFERENCE TO RELATED APPLICATION

This non-provisional patent application claims priority to, and claims the benefits of, U.S. Provisional Patent Application No. 63/281,219, titled “HATS, CAPS, AND METHODS FOR MANUFACTURING THE SAME”, filed Nov. 19, 2021, the disclosure of which is incorporated herein, in its entirety, by reference.

BACKGROUND

A biretta is a square hat that is often worn by religious officials and academics. Conventional birettas are made entirely from silk or wool and thus are easily damaged by squashing because of chafing of the fabric when the biretta is folded. Accordingly, conventional birettas are disposable. Various other types of hats and caps that are made entirely from silk or wool are also easily damaged by squashing. The instant disclosure, therefore, identifies and addresses a need for improved hats, caps, and methods for manufacturing the same.

SUMMARY

As will be described in greater detail below, the instant disclosure describes various hats, caps, and methods for manufacturing the same. In non-limiting examples, provided are hats with a non-woven heat-activated low-melt polyester fiber as a foundation, caps with a non-woven heat-activated low-melt polyester fiber as a foundation, and methods for manufacturing the hats and caps with non-woven heat-activated low-melt polyester fiber as foundations. A non-limiting example of a provided hat with a non-woven heat-activated low-melt polyester fiber as a foundation is a biretta having a non-woven heat-activated low-melt polyester fiber as a foundation.

In an embodiment, provided is a biretta including (i) a plastic biretta hat foundation having a first exterior ridge, where the plastic biretta hat foundation is formed from plastic and (ii) a first horn foundation having a first base portion fastened along the first exterior ridge of the plastic biretta hat foundation, where the first horn foundation is formed from the same composition of plastic as the plastic biretta hat foundation.

In an embodiment, the biretta can include a second horn foundation having a second base portion fastened along a second exterior ridge of the plastic biretta hat foundation, where the second horn foundation comprises the same composition of plastic as the plastic biretta hat foundation. In some examples, the biretta can include a third horn foundation having a third base portion fastened along a third exterior ridge of the plastic biretta hat foundation, where the third horn foundation comprises the same composition of plastic as the plastic biretta hat foundation. In examples, the first exterior ridge of the plastic biretta hat foundation, the second exterior ridge of the plastic biretta hat foundation, and the third exterior ridge of the plastic biretta hat foundation are different exterior ridges. In some examples, the biretta can have four horns.

In some embodiments, the plastic of which the plastic biretta hat foundation is formed can be a thermoplastic. In some examples, the plastic is a non-woven heat-activated polyester fiber material that has been activated. In some examples, the activated polyester fiber material has an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit, inclusive.

In some embodiments, the plastic of which the plastic biretta hat foundation is formed can be a thermosetting plastic.

In some examples, the biretta can include a fabric cover fastened to the plastic biretta hat foundation. In some embodiments, the fabric cover can cover at least a portion of an exterior of the plastic biretta hat foundation.

In some embodiments, the plastic biretta hat foundation can define an orifice. In some examples, the plastic biretta hat foundation can define the orifice at a peak of the plastic biretta hat foundation. In some embodiments, the biretta can include a portion of a twist rope passing through the orifice. In some embodiments, the biretta can include a pom having a pom fastener, where a portion of the pom fastener passes through the orifice.

In an embodiment, a method for fabricating a biretta can include (i) forming, using a hat block, a plastic biretta hat foundation from a non-woven heat-activated low-melt polyester fiber, (ii) forming, using a horn block, at least one plastic biretta horn from the same composition of non-woven heat-activated low-melt polyester fiber, and (iii) fastening the at least one plastic biretta horn along a first exterior ridge of the plastic biretta hat foundation.

In some examples, the forming the plastic biretta hat foundation can include applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the hat block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta hat foundation.

In some examples, the forming the plastic biretta hat foundation can include activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit.

In some examples, the forming the plastic biretta horn can include applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the horn block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta horn.

In some examples, the forming the plastic biretta horn can include activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit.

In some embodiments, the method can include forming an orifice in the plastic biretta hat foundation. In some embodiments, the orifice can be formed at a peak of the plastic biretta hat foundation. In some embodiments, the method can include passing a portion of a twist rope passing through the orifice to affix the twist rope to the plastic biretta hat foundation. In some embodiments, the method can include passing a pom fastener through the orifice to affix a pom to the plastic biretta hat foundation.

In some embodiments, the method can include fastening a fabric cover to the plastic biretta hat foundation such that the fabric cover covers at least a portion of an exterior of the plastic biretta hat foundation.

Features from any of the embodiments described herein can be used in combination with one another in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The inventive features characteristic of the teachings and advantages thereof are better understood from the detailed description and the accompanying drawings. The accompanying drawings describe examples of the present teachings and are not limiting.

FIG. 1 depicts a perspective view of an exemplary biretta.

FIG. 2 depicts a bottom view of the exemplary biretta of FIG. 1 .

FIG. 3 depicts a front and side perspective view of the exemplary biretta of FIG. 1 .

FIG. 4 depicts a flowchart of an exemplary method for fabricating a biretta.

FIG. 5 depicts a perspective view of an exemplary hat block.

FIG. 6 depicts a top view of the exemplary hat block of FIG. 5 .

FIG. 7 depicts a side view of the exemplary hat block of FIG. 5 .

FIG. 8 depicts a side view of a plastic biretta hat foundation.

FIG. 9 depicts a top and side exterior perspective view of the plastic biretta hat foundation of FIG. 8 .

FIG. 10 depicts a bottom interior and side exterior perspective view of the plastic biretta hat foundation of FIG. 8 .

FIG. 11 depicts a side and top perspective view of an exemplary horn block.

FIG. 12 depicts a perspective view of the exemplary horn block of FIG. 11 .

FIG. 13 depicts a side view of the exemplary horn block of FIG. 11 .

FIG. 14 depicts a side view of exemplary non-woven heat-activated low-melt polyester fiber formed in the shape of a plastic biretta horn foundation upon the exemplary horn block of FIG. 11 .

FIG. 15 depicts a side view of the plastic biretta horn foundation.

FIG. 16 depicts a perspective view of an exemplary application of adhesive to the plastic biretta hat foundation during a process to attach the plastic biretta horn foundation to the plastic biretta hat foundation.

FIG. 17 depicts a perspective view of the plastic biretta hat foundation having one exemplary plastic biretta horn foundation attached to an exterior ridge of the plastic biretta hat foundation.

FIG. 18 depicts a perspective view of the plastic biretta hat foundation having three exemplary plastic biretta horn foundations attached to respective exterior ridges of the plastic biretta hat foundation.

FIG. 19 depicts a perspective view of the plastic biretta hat foundation having three exemplary plastic biretta horn foundations attached to the respective exterior ridges of the plastic biretta hat foundation.

FIG. 20 depicts a perspective view of two sides of the plastic biretta hat foundation fastened together with an adhesive to form a corner.

FIG. 21 depicts a plan view of one-quarter of an exemplary fabric cover that is marked using a pattern.

FIG. 22 depicts a side view of an exemplary fabric cover and the plastic biretta hat foundation during an exemplary fastening of the fabric cover to the plastic biretta hat foundation.

FIG. 23 depicts a perspective view of the exemplary biretta, including a twist rope affixed to the plastic biretta hat foundation.

FIG. 24 depicts a bottom view of a pom fastener passing through an orifice to affix a pom to the plastic biretta hat foundation, as well as an exemplary fastening of the fabric cover to the plastic biretta hat foundation.

In accordance with common practice, the features depicted by the drawings may not be drawn to scale. Accordingly, the dimensions of the depicted features may be arbitrarily expanded or reduced for clarity. In accordance with common practice, some of the drawings are simplified for clarity. Thus, the drawings may not depict all components of a particular apparatus or method. Further, like reference numerals denote like features throughout the specification and figures.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present disclosure is generally directed to hats, caps, and methods for manufacturing the same. In non-limiting examples, provided are hats with a plastic foundation, caps with a plastic foundation, and methods for manufacturing the hats and caps with plastic foundations. A non-limiting example of a biretta with a non-woven heat-activated low-melt polyester fiber as a foundation is provided.

In some examples, the provided techniques can be used to fabricate a biretta. For example, fabricating a biretta can include (1) forming, using a hat block, a plastic biretta hat foundation from a non-woven heat-activated low-melt polyester fiber, (2) forming, using a horn block, at least one plastic biretta horn from the same type of non-woven heat-activated low-melt polyester fiber, and (3) fastening a plastic biretta horn along an exterior ridge of the plastic biretta hat foundation. An orifice can be formed in a peak of the plastic biretta hat foundation. At least a part of the plastic biretta hat foundation can be covered with a fabric cover. A twist rope or a pom fastener can be passed through the orifice to secure the twist rope or a pom to the plastic biretta hat foundation.

The provided techniques can advantageously be used to fabricate hats and caps, such as birettas, that are durable, squash resistant, longer-lasting, and combinations thereof.

The following provides, with reference to FIGS. 1-24 , detailed descriptions of aspects of example hats, caps, and methods for manufacturing the same.

FIG. 1 depicts a perspective view of an exemplary biretta 100 fabricated with a plastic biretta hat foundation (e.g., plastic biretta hat foundation 800 depicted in FIG. 8 ) and three plastic biretta horn foundations (e.g., plastic biretta horn foundation 1400 depicted in FIG. 14 ). In some examples, the plastic biretta hat foundation 800, the plastic biretta horn foundations 1400, or both, can be formed from a non-woven heat-activated low-melt polyester fiber.

The perspective view in FIG. 1 shows the exterior top 105 of the biretta 100. The biretta 100 includes three biretta horns 110A, 110B, 110C and a twist rope 115. The exterior top 105 of the biretta 100 includes four exterior ridges 120A, 120B, 120C, 120D. The three biretta horns 110A, 110B, 110C are each located along a respective exterior ridge 120A, 120B, 120C. In this example, the twist rope 115 is fastened to the plastic biretta hat foundation 800 at a peak 125 of the exterior top 105 of the biretta 100. FIG. 1 depicts a fabric cover 130 covering the plastic biretta hat foundation 800 and the three plastic biretta horn foundations 1400.

FIG. 2 depicts a bottom view of the exemplary biretta 100. The bottom view in FIG. 2 shows the interior bottom 200 of the biretta 100, including a lining 205. The lining 205 can be formed from fabrics such as silk, polyester, wool, or cotton. In examples, the lining 205 can be adhered to the fabric cover 130 with adhesive, thread, or a combination thereof. The lining 205 can be fastened to an interior of the plastic biretta hat foundation 800 (e.g., with adhesive). A manufacturer identification label 210 can be adhered to the fabric cover 130, with adhesive, thread, or a combination thereof.

FIG. 3 depicts a front and side perspective view 300 of the exemplary biretta 100. FIG. 3 shows that sides 305A, 305B of the biretta 100 slope slightly inward from the widest portion of the biretta 100 to the bottom of the biretta 100.

FIG. 4 depicts a flowchart of an exemplary method for fabricating a biretta 400, such as the biretta 100.

As depicted at step 402, the method for fabricating a biretta 400 can include forming, using a hat block (e.g., hat block 500 depicted in FIG. 5 ), a plastic biretta hat foundation 800 from a non-woven heat-activated low-melt polyester fiber.

FIG. 5 depicts a perspective view of an exemplary hat block 500. Non-woven heat-activated low-melt polyester fiber can be formed around the hat block 500 to fabricate the plastic biretta hat foundation 800.

In some examples, the hat block 500 can be made from a carveable material such as polystyrene or wood. The size of the biretta 100 can be determined by the needs of the end user.

In some examples, the bottom of the hat block 500 can be made in ½″ size increments from 21½″ to 25.″ Each length of the bottom of the hat block 500 can represent ¼ of a total head size. The bottom of the hat block 500 can rise 2½″ to an angled outer edge of the hat block 500 on the sides of the hat block 500. The angle of the hat block 500 can be determined by the side to side distance of the edge of the hat block 500. The horizontal length of the outer edge of the hat block 500 can be the width of the bottom of the hat block 500 plus 3 cm. The middle peak at the top of the hat block 500 can be 4″ from the bottom of the hat block 500. The top of the hat block 500 can angle down like a pyramid to an outer edge of the hat block 500. Surfaces of the hat block 500 can be sanded to a smooth surface texture. Acrylic varnish can be applied to surfaces of the hat block 500 to lightly coat the hat block 500.

In some embodiments, the forming the plastic biretta hat foundation 800 can include applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the hat block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta hat foundation 800.

In some examples, the non-woven heat-activated low-melt polyester fiber that forms the plastic biretta hat foundation 800 can be cut 13″ to 14″ square. The non-woven heat-activated low-melt polyester fiber can be draped evenly over the hat block 500 and pinned to the hat block 500 along the flat underside of the hat block 500. Three of four corners of the plastic biretta hat foundation 800 can be basted from the bottom of the hat block 500 at the angled corners to the corner of the outer edge and the triangular piece can be cut off close to the stitching. The fourth corner of the plastic biretta hat foundation 800 can be pinned together with long glass head pins. Glass head pins can withstand heat to avoid melting as would happen with plastic head sewing pins.

In some examples, the plastic biretta hat foundation 800 can be formed from a thermoplastic. In some examples, the plastic biretta hat foundation 800 can be formed from a thermosetting plastic.

FIG. 6 depicts a top view of the exemplary hat block 500. Four exterior ridges 505A, 505B, 505C, 505D of the hat block 500 are used to form the four exterior ridges 120A, 120B, 120C, 120D of the plastic biretta hat foundation.

FIG. 7 depicts a side view of the exemplary hat block 500. Sides 510A, 510B of the hat block 500 form the sides 305A, 305B of the plastic biretta hat foundation 800.

FIG. 8 depicts a side view of the plastic biretta hat foundation 800. The plastic biretta hat foundation 800 can be formed of non-woven heat-activated low-melt polyester fiber 805 formed in the shape of the plastic biretta hat foundation 800 by the hat block 500. In some examples, the sides of the plastic biretta hat foundation 800 may define at least one gap 810 where the sides otherwise would intersect. The gap 810 can advantageously be used to release any tension occurring between sides of the plastic biretta hat foundation 800 and the hat block 500 during removal of the plastic biretta hat foundation 800 from the hat block 500.

In some examples, the forming the plastic biretta hat foundation 800 can include activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation 800 by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation 800 to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit, inclusive. Following activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation 800, any excess activated low-melt polyester fiber can be trimmed.

In some examples, the non-woven heat-activated low-melt polyester fiber can be activated by pressing the non-woven heat-activated low-melt polyester fiber with a hot iron using steam conservatively on the flat sides of the plastic biretta hat foundation 800. Then, the flat top facets of the pyramid of the plastic biretta hat foundation 800 can be pressed in the same manner. After the sides of the plastic biretta hat foundation 800 have been activated and stiffened to the shape of the hat block 500, the plastic biretta hat foundation 800 can be removed from the hat block 500. The glass head pins can be removed permitting the plastic biretta hat foundation 800 to be extricated from the hat block 500. In some embodiments, the open corner of the plastic biretta hat foundation 800 can be sewn together, fastened, melded together with the use of hot adhesive glue and trimmed, or a combination thereof.

FIG. 9 depicts a top and side exterior perspective view of the plastic biretta hat foundation 800 after the plastic biretta hat foundation 800 is removed from the hat block 500. FIG. 9 also depicts the four exterior ridges 120A, 120B, 120C, 120D of the plastic biretta hat foundation.

FIG. 10 depicts a bottom interior and side exterior view of the plastic biretta hat foundation 800 after the plastic biretta hat foundation 800 is removed from the hat block 500. FIG. 10 also depicts the gap 810.

Returning to FIG. 4 , as depicted at step 404, the method for fabricating a biretta 400 can include forming, using a horn block, at least one plastic biretta horn from the same composition of non-woven heat-activated low-melt polyester fiber.

FIG. 11 depicts a side and top perspective view of an exemplary horn block 1100. Non-woven heat-activated low-melt polyester fiber can be formed around the horn block 1100 and subsequently activated to fabricate the plastic biretta horn foundation 1400. FIG. 12 depicts a perspective view of the exemplary horn block 1100. FIG. 13 depicts a side view of the exemplary horn block 1100.

In some examples, the horn block 1100 can be made from a carveable material such as polystyrene or wood. The horn block 1100 can be carved with the following dimensions: 1″ deep and 3½ cm from a base portion edge (e.g., base portion 1500 as depicted in FIG. 15 ) to a center top of the arc. The width of the horn block 1100 portion corresponding to the base portion 1500 can be determined by the length of the four exterior ridges 505A, 505B, 505C, 505D of the pyramid for the biretta 100 being shaped. Acrylic varnish can be applied to surfaces of the horn block 1100 to lightly coat the horn block 1100.

In some embodiments, the forming the plastic biretta horn foundation 1400 can include applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the horn block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta horn.

In examples, a piece of heat-activated low-melt polyester fiber can be loosely draped over the horn block 1100 and pinned on all sides of the 1″ depth with glass head pins. This can be completed three or four times for the biretta 100. The iron can be pressed on a flat side of the horn block 1100 until the heat-activated low-melt polyester fiber is activated and then the heat-activated low-melt polyester fiber can be removed from the horn block 1100 and trimmed to the edge, thus forming the base portion 1500 and the arc portion of the plastic biretta horn foundation 1400.

In some examples, the plastic biretta horn foundation 1400 can be formed from a thermoplastic. In some examples, the plastic biretta horn foundation 1400 can be formed from a thermosetting plastic.

FIG. 14 depicts a side view of exemplary non-woven heat-activated low-melt polyester fiber formed in the shape of the plastic biretta horn foundation 1400 upon the horn block 1100.

In some examples, the forming the plastic biretta horn can include activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit, inclusive. Following activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn, any excess activated-melt polyester fiber of the plastic biretta horn can be trimmed.

In some examples, the non-woven heat-activated low-melt polyester fiber can be activated by pressing the non-woven heat-activated low-melt polyester fiber with a hot iron using steam conservatively on a flat side of the plastic biretta horn foundation 1400. After the side of the plastic biretta horn foundation 1400 has been activated and stiffened to the shape of the horn block 1100, the plastic biretta horn foundation 1400 can be removed from the horn block 1100. The glass head pins can be removed permitting the plastic biretta horn foundation 1400 to be extricated from the horn block 1100. In some embodiments, the open corner of the plastic biretta horn foundation 1400 can be sewn together, fastened, melded together with the use of hot adhesive glue and trimmed, or a combination thereof.

FIG. 15 depicts a side view of the plastic biretta horn foundation 1400. FIG. 15 also depicts the base portion 1500 of the plastic biretta horn foundation 1400.

Returning to FIG. 4 , as depicted at step 406, the method for fabricating a biretta 400 can include fastening the at least one plastic biretta horn foundation 1400 to the plastic biretta hat foundation 800 along the exterior ridge 120A of the plastic biretta hat foundation 800. Additional plastic biretta horn foundations 1400 can be fastened to the respective exterior ridges 120B, 120C, 120D. In some examples, between one and four of the plastic biretta horn foundations 1400 can be fastened to the respective exterior ridges 120A, 120B, 120C, 120D of the plastic biretta hat foundation 800. The plastic biretta horn foundations 1400 can be fastened to the respective exterior ridges 120B, 120C, 120D with adhesive, by melting, by taping, by sewing, by ultrasonic welding, by stapling, or a combination thereof.

In some examples, three plastic biretta horn foundations 1400 can be affixed to three of the four respective exterior ridges 120A, 120B, 120C, 120D of the plastic biretta hat foundation 800 by applying a line of glue along the respective exterior ridge and holding the respective plastic biretta horn foundations 1400 perpendicular to the top of the plastic biretta hat foundation 800 until the heat of the glue affixes the plastic biretta horn foundations 1400 to the plastic biretta hat foundation 800.

FIG. 16 depicts a perspective view of one plastic biretta horn foundation 1400 while an adhesive 1605 is applied to the exterior ridge 120A of the plastic biretta hat foundation 800 while fastening the at least one plastic biretta horn foundation 1400 to the plastic biretta hat foundation 800 along the exterior ridge 120A of the plastic biretta hat foundation 800.

FIG. 17 depicts a perspective view of the plastic biretta hat foundation 800 having one exemplary plastic biretta horn foundation 1400 attached to the exterior ridge 120A.

FIG. 18 depicts a perspective view of the plastic biretta hat foundation 800 having three exemplary plastic biretta horn foundations 1800A, 1800B, 1800C respectively attached to the exterior ridges 120A, 120B, 120C. The three exemplary plastic biretta horn foundations 1800A, 1800B, 1800C can be duplicates of the plastic biretta horn foundation 1400.

In a nonlimiting example, the plastic biretta hat foundation 800, at least one plastic horn foundation 1400, or combination thereof can be formed by injection molding plastic into a respectively configured mold. By using this technique, the plastic biretta hat foundation 800 and the at least one plastic horn foundation 1400 can be formed as a unitary foundation for the biretta 100.

Returning to FIG. 4 , as depicted at step 408, the method for fabricating a biretta 400 can include forming an orifice (e.g., the orifice 1900 depicted in FIG. 19 ) in the plastic biretta hat foundation, such that the plastic biretta hat foundation 800 defines the orifice 1900. In some examples, the orifice 1900 can be formed at the peak 125 of the plastic biretta hat foundation. The peak 125 of the plastic biretta hat foundation 800 can be located at an intersection point of the four exterior ridges 120A, 120B, 120C, 120D. The orifice 1900 can be formed by drilling, punching, molding the plastic biretta hat foundation 800 around a dowel prior to activating the non-woven heat-activated low-melt polyester fiber, or combination thereof.

FIG. 19 depicts a perspective view of the plastic biretta hat foundation 800 having three exemplary plastic biretta horn foundations 1400 respectively attached to the exterior ridges 120A, 120B, 120C. FIG. 19 also depicts the plastic biretta hat foundation 800 defining the orifice 1900.

FIG. 20 depicts a perspective view of two sides of the plastic biretta hat foundation 800 fastened together with an adhesive 2000 to form a corner. The gap 810 can optionally be closed, filled, or a combination thereof by applying adhesive to the two sides of the plastic biretta hat foundation 800 that define the gap 810.

Returning to FIG. 4 , as depicted at step 410, the method for fabricating a biretta 400 can include fastening a fabric cover 130 to the plastic biretta hat foundation 800 such that the fabric cover 130 covers at least a portion of an exterior of the plastic biretta hat foundation 800. The fabric cover 130 can be fabricated of wool, silk, cotton, or combination thereof.

In some examples, a pattern having a desired size of the Biretta 100 can be used to fabricate the fabric cover 130. The fabric cover 130 can be made from either three or four pieces, depending on desired seams and pattern, and sewn together using a quilting technique to achieve an equal center of the Biretta 100.

FIG. 21 depicts a plan view of one-quarter of an exemplary fabric cover 130 that is marked using a pattern. Four of the quarters of the exemplary fabric cover 130 can be affixed to each other, affixed to the plastic biretta hat foundation 800, affixed to at least one of the plastic biretta horn foundations 1400 or combination thereof. In examples, the quarters of the exemplary fabric cover 130 can be affixed by adhesive, by melting, by taping, by sewing, by ultrasonic welding, by stapling, or a combination thereof.

FIG. 22 depicts a side view of the exemplary fabric cover 130 and the plastic biretta hat foundation 800 during an exemplary fastening of the fabric cover 130 to the plastic biretta hat foundation 800. FIG. 22 also depicts the fabric cover 130 covering at least the portion of the plastic biretta hat foundation 800 and the plastic biretta horn foundation 1400.

In some examples, the biretta 100 may include a sweatband. The sweatband can be formed from a piece of grosgrain ribbon measured to a correct size and gently swirled using a steam iron. The sweatband can be pinned inside the biretta 100 at a brim edge covering a free edge of the fabric cover 130. The free edge of the fabric cover 130 can be basted and then the sweatband and the fabric cover 130 can be sewn together on a cylinder arm sewing machine. Following sewing sweatband to the fabric cover 130, the baste stitches can be removed.

In some examples, the biretta 100 may include the lining 205. The lining 205 can be fabricated from wool, silk, cotton, or a combination thereof. The lining 205 can be cut from a lining pattern. Darts can be sewn on the backside of lining 205 for each of the four corners. The lining 205 can be fitted inside the Biretta 100 and folded down to hide the free edge behind the lining and tucked under the sweatband. A hidden baste stitch can hold the lining 205 in place.

In some embodiments, a seam can be sewn in the fabric cover 130 where a portion of the fabric cover 130 covers a portion of the plastic biretta horn foundation 1400 where the plastic biretta horn foundation 1400 meets one of the four exterior ridges 120A, 120B, 120C, 120D. The seam can be sewn from an outer corner of the fabric cover 130 to the center of the fabric cover 130 to keep the fabric cover 130 firmly in place, maintaining the sharp geometric lines of the finished biretta 100.

As depicted at step 412, the method for fabricating a biretta 400 can include passing a portion of a twist rope 115, a pom fastener 2400, or both through the orifice 1900 to affix the twist rope 2300, a pom, or both to the plastic biretta hat foundation 800.

FIG. 23 depicts a perspective view of biretta 100, including the twist rope 115 affixed to the plastic biretta hat foundation 800, as well as an exemplary fastening of the fabric cover 130 to the plastic biretta hat foundation 800.

FIG. 24 depicts the interior bottom 200 with the pom fastener 2400 passing through the orifice 1900 to affix the pom to the plastic biretta hat foundation 800, as well as an exemplary fastening of the fabric cover 130 to the plastic biretta hat foundation 800. In examples, the Pom fastener 2400 can be thread, cord, rope, or a combination thereof.

As detailed above, the steps outlined in the method for fabricating a biretta 400 in FIG. 4 may provide methods for fabricating hats, caps, or a combination thereof. In examples, the provided methods may be used to fabricate the biretta 100. By doing so, in examples, the systems and methods described herein may improve conventional headwear by providing headwear that is durable and squash-resistant.

As used hereby, the term “example” means “serving as an example, instance, or illustration.” Any example described as an “example” is not necessarily to be construed as preferred or advantageous over other examples. Likewise, the term “examples” does not require all examples include the discussed feature, advantage, or mode of operation. Use of the terms “in one example,” “an example,” “in one feature,” and/or “a feature” in this specification does not necessarily refer to the same feature and/or example. Furthermore, a particular feature and/or structure can be combined with one or more other features and/or structures. Moreover, at least a portion of at least one method described hereby can produce at least a portion of an apparatus (e.g., a hat, a cap) described hereby. A reference using a designation such as “first,” “second,” and so forth does not limit either the quantity or the order of those elements. Rather, these designations are used as a convenient method of distinguishing between two or more elements or instances of an element. Thus, a reference to first and second elements does not mean only two elements can be employed, or the first element must necessarily precede the second element. Also, unless stated otherwise, a set of elements can comprise one or more elements. In addition, terminology of the form “at least one of: A, B, or C” or “one or more of A, B, or C” or “at least one of the group consisting of A, B, and C” used in the description or the claims can be interpreted as “A or B or C or any combination of these elements.” For example, this terminology can include A, or B, or C, or A and B, or A and C, or A and B and C, or 2A, or 2B, or 2C, and so on.

The terminology used hereby is for the purpose of describing particular examples only and is not intended to be limiting. As used hereby, the singular forms “a,” “an,” and “the” include the plural forms as well, unless the context clearly indicates otherwise. In other words, the singular portends the plural, where practicable. Further, the terms “comprises,” “comprising,” “includes,” and “including,” specify a presence of a feature, an integer, a step, a block, an operation, an element, a component, and the like, but do not necessarily preclude a presence or an addition of another feature, integer, step, block, operation, element, component, and the like.

Nothing stated or depicted in this application is intended to dedicate any component, step, block, feature, object, benefit, advantage, or equivalent to the public, regardless of whether the component, step, block, feature, object, benefit, advantage, or the equivalent is recited in the claims. While this disclosure describes examples, changes and modifications can be made to the examples disclosed hereby without departing from the scope defined by the appended claims. The present disclosure is not intended to be limited to the specifically disclosed examples alone. 

What is claimed is:
 1. A biretta, comprising: a plastic biretta hat foundation having a first exterior ridge, wherein the plastic biretta hat foundation is formed from plastic; and a first horn foundation having a first base portion fastened along the first exterior ridge of the plastic biretta hat foundation, wherein the first horn foundation is formed from the same composition of plastic as the plastic biretta hat foundation.
 2. The biretta of claim 1, further comprising a second horn foundation having a second base portion fastened along a second exterior ridge of the plastic biretta hat foundation, wherein the second horn foundation comprises the same composition of plastic as the plastic biretta hat foundation.
 3. The biretta of claim 2, further comprising a third horn foundation having a third base portion fastened along a third exterior ridge of the plastic biretta hat foundation, wherein the third horn foundation comprises the same composition of plastic as the plastic biretta hat foundation.
 4. The biretta of claim 1, wherein the plastic is a thermoplastic.
 5. The biretta of claim 4, wherein the plastic is a non-woven heat-activated polyester fiber material that has been activated.
 6. The biretta of claim 5, wherein the activated polyester fiber material has an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit, inclusive.
 7. The biretta of claim 1, wherein the plastic is a thermosetting plastic.
 8. The biretta of claim 1, further comprising a fabric cover fastened to the plastic biretta hat foundation and covering at least a portion of the exterior of the plastic biretta hat foundation.
 9. The biretta of claim 1, wherein the plastic biretta hat foundation defines an orifice.
 10. The biretta of claim 9, wherein the plastic biretta hat foundation defines the orifice at a peak of the plastic biretta hat foundation.
 11. The biretta of claim 9, further comprising a portion of a twist rope passing through the orifice.
 12. The biretta of claim 9, further comprising a pom having a pom fastener, wherein a portion of the pom fastener passes through the orifice.
 13. A method for fabricating a biretta, comprising: forming, using a hat block, a plastic biretta hat foundation from a non-woven heat-activated low-melt polyester fiber; forming, using a horn block, at least one plastic biretta horn from the same composition of non-woven heat-activated low-melt polyester fiber; and fastening the at least one plastic biretta horn along a first exterior ridge of the plastic biretta hat foundation.
 14. The method of claim 13, wherein the forming the plastic biretta hat foundation further comprises applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the hat block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta hat foundation.
 15. The method of claim 14, wherein the forming the plastic biretta hat foundation further comprises activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit.
 16. The method of claim 13, wherein the forming the plastic biretta horn further comprises applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the horn block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta horn.
 17. The method of claim 16, wherein the forming the plastic biretta horn further comprises activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit.
 18. The method of claim 13, further comprising forming an orifice in the plastic biretta hat foundation.
 19. The method of claim 18, wherein the orifice is formed at a peak of the plastic biretta hat foundation.
 20. The method of claim 13, further comprising fastening a fabric cover to the plastic biretta hat foundation such that the fabric cover covers at least a portion of an exterior of the plastic biretta hat foundation. 